Building panel

ABSTRACT

Building panels adapted to form the exterior enclosure of a prefabricated home are disclosed. The building panels are a sandwich composed of masonry elements such as bricks, synthetic polyester mortar, reinforcing wire mesh, a polymer foam, and a suitable inner facing layer, all held together by the mortar and foam. The method includes placing bricks in the desired arrangement of a support layer, joining the bricks by applying polyester mortar to the back side of the bricks and between adjacent bricks, applying the reinforcing wire mesh within the mortar, spacing the outer facing layer from the wire mesh, and then introducing a foam polymer which is cured in the space between the wire mesh polyester and the outer facing layer.

nited States Patent [1 1 Weiner Mar. 4, 1975 1 BUILDING PANEL 211 App].No.: 105,686

Related US. Application Data [63] Continuation-in-part of Ser. No.20,764, March 18,

1970, abandoned.

[52] US. Cl 52/309, 52/315, 264/35, 264/261 [51] Int. Cl. E046 2/24 [58]Field of Search 52/315, 309, 314, 311

[56] References Cited UNITED STATES PATENTS 2,046,213 6/1936 Schnurer52/314 X 2,781,554 2/1957 Robinson 52/309 3,192,671 7/1965 Smith 52/586X 3,230,681 1/1966 Allen 52/586 3.239.982 3/1966 Nicosia 52/3093,304,673 2/1967 Ramoneda 52/314 3,327,442 6/1967 Hermann 52/3093,462,897 8/1969 Weinrott..... 52/169 3,521,418 7/1970 Bart0l0ni....52/315 3,646,180 2/1972 Winwick 52/309 3.646.715 3/1972 Pope 52/315FOREIGN PATENTS OR APPLlCATlONS 1,439,196 4/1966 France 52/309 OTHERPUBLICATIONS Molding Rigid Urethane Foamff by Elastomer Chemical Dept.of E. l. du Pont de Nemours 1nc., pp. 1 and 11.

Primary E.\'aminer-John E. Murtagh Attorney, Agent, or FirmSeidel, Gonda& Goldhammer [5 7] ABSTRACT Building panels adapted to form the exteriorenclosure of a prefabricated home are disclosed. The building panels area sandwich composed of masonry elements such as bricks, syntheticpolyester mortar, reinforcing wire mesh, a polymer foam, and a suitableinner facing layer, all held together by the mortar and foam. The methodincludes placing bricks in the desired arrangement of a support layer,joining the bricks by applying polyester mortar to the back side of thebricks and between adjacent bricks, applying the reinforcing wire meshwithin the mortar, spacing the outer facing layer from the wire mesh,and then introducing a foam polymer which is cured in the space betweenthe wire mesh polyester and the outer facing layer.

6 Claims, 11 Drawing Figures PATENTEDHAR 4192s 3,868,801

' sum 1 {If 3 //V VEN GERSHE/V WE ER PATENTEDHAR 41375 SHEET 2 95 3 m hm. //v|//v TOR GERSHEV'N "WE/IVER A TTOR/VE V5 BUILDING PANEL This patentapplication is a continuation-in-part of my patent application Ser. No.20,764 filed Mar. 18, 1970, now abandoned, entitled: Building Panel AndMethod Of Making Same.

The present invention is directed to prefabricated building panels and amethod of making the same. The building panels ofthe present inventionare desirably of suitable dimensions whereby they may be positioned on afoundation and supported in a manner whereby they form the perimeterwall of a dwelling. One surface of the panel constitutes the outer faceof the dwelling, while the opposite surface of the panel constitutes theexposed wall of a room in the dwelling. In order to accomplish theseobjects, l prefer to make panels that are 4 feet wide and 9 feet high.While these dimensions represent the most convenient size in terms ofeconomics and raw materials, other sizes may be utilized. In thisregard, it is contemplated that the smaller size panels are oftennecessary for the top and bottom window sections. ,1

The panels utilized in forming the perimeter of a wall of a dwellinginclude planar panels and corner panels which are generally L-shaped.There is described hereinafter the specific details with respect to theplanar panels and method of making the same. The following descriptionapplies equally well to the corner or L- shaped panels.

The panels of the present invention are manufactured on a conveyorwhereby the layer ofthe panels be comes increasingly thicker up to thefinished thickness of the panels. The first layer of the sandwich panelof the present invention which is applied to the conveyor is the masonryelements such as bricks which form the exterior surface of the dwelling.Thereafter, the bricks are laterally joined to each other and providedwith a coating across their uppermost surface of a polyester mortar. Areinforcing wire mesh is thereafter applied within the polyester mortaron the back of the bricks. Additional polyester mortar may be added sothe polyester mortar penetrates through the wire mesh. Thereafter, aninner facing layer representing the wall on the inside of the dwellingis positioned on the mold so as to be spaced from the wire mesh. Betweenthe polyester mortar at the back of the brick and the inner facinglayer. a low density organic insulation, such as a cellular core foammaterial is introduced and cured in situ.

It is an object of the present invention to provide a novel low densityheat insulating building panel which is simple, economical to build, andreliable for use in constructing the wall of the prefabricated building.

Other objects will appear hereinafter.

For the purpose of illustrating the invention, there are shown in thedrawings forms which are presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is a partial perspective view of a wall constructed with thebuilding panels of the present invention.

FIG. 2 is a sectional view taken along the line 22 in FIG. 1.

FIG. 3 is a sectional view taken along the line 3-3 in FIG. 1.

FIG. 4 is a partial perspective view ofa building panel of the presentinvention being manufactured, and illustrating various components of thepanel.

FIG. 5 is a sectional view taken along the line S-5 in FIG. 4 andillustrates the first step in the process.

FIG. 6 is a sectional view taken along the line 6-6 in FIG. 1 andillustrates the second step in the process.

FIG. 7 is a sectional view taken along the line 7-7 in FIG. 4 andillustrates the next step in the process.

FIG. 8 is a sectional view taken along the line 8-8 in FIG. 4 andillustrates the next step in the process.

FIG. 9 is a sectional view taken along the line 99 and illustrates thenext step in the process.

FIG. 10 is a sectional view taken along the line 10l0 in FIG. 1 andillustrates the last step of the process.

FIG. 11 is a partial perspective view of a panel in accordance with thepresent invention.

Referring to the drawing in detail, wherein like numerals indicate likeelements, there is shown in FIG. I a wall of a building comprised ofpanels 10 and 10 made in accordance with the present invention. Thepanels have been inserted into a top channel 12 and a bottom channel 14.Channel 14 rests on the foundation 16. The wall illustrated in FIG. 1 iscomprised of panels 10 and 10' which have been interconnected by aspline 20 and facing bricks which have been field applied after thepanels have been interconnected and positioned within the channels 12and 14. The field applied bricks are brick 18 and those directlytherebelow in every other row. The remainder of the wall of the dwellingis similarly formed with interconnected panels made in accordance withthe present invention.

As shown more clearly in FIGS. 2 and 3, each of the panels 10 and 10 areidentical and include an exterior surface of the wall defined by bricks22 vertically and horizontally interconnected with each other by mortar24 of a type described hereinafter. A layer of the polyester mortar 24is applied to the rear surface of the bricks 22. A reinforcement wiremesh 26 is interposed within the layer of mortar 24 and a layer of lowdensity organic insulation such as foam polymer 28. Except around theedges of the panels which are concealed during installation, foampolymer layer 28 is completely concealed to prevent deterioration fromultra violet light. The inner surface of the wall defining the roomwithin the dwelling is the inner facing layer 30.

The inner facing layer 30 may be any one of a wide variety ofprefinished materials utilized heretofore as defining the surface ofwalls in buildings such Gypsum board, sheet rock, prefinished plywoodpanels, etc. The foam polymer layer 28 may be any one of a wide vari etyof commericially available urethane foams having closed cells andparticularly adapted for use as insulation against heat or cold. While awide variety of such urethane foams are available for use as insulation(see discussion of polyurethane foams for insulation purposes set forthin Rigid Plastic Foams, by T. H. Ferrigno, Reinhold PublishingCorporation, Second Edition, pages through 183), I prefer to use theElectrofoam urethane foam system of PPG Industries, Inc. of Pittsburgh,Pa., described hereinafter, having a low K factor. These polyurethanefoams have the lowest K factor of all commercial insulation materials,and are slow rise foams permitting even distribution, and may be appliedby frothing.

The bricks 18 and 22 are thinner than conventional bricks but areotherwise of the same dimensions and configurations. I prefer to usebricks 18 and 22 with a thickness measured from front to back of aboutthreeeighths to five-eighths inches. The mortar 24 joins adjacent bricksin all horizontal and vertical directions and must be a fast dryingmortar capable of acting as an adhesive so that it may perform thisbonding function. I prefer to use as the mortar 24 a mixture of sand anda polyester resin which may be poured or sprayed. If desired, a coloringpigment and an ultra violet inhibitor can be added to the mixture. Whilethe percentage of sand and polyester resin may be varied as desired, Iprefer to use 60 to 80 percent by weight of sand and 40 to 20 percent byweight of polyester.

The preferred polyester resin used by me is Selectron No. 5265 having aspecific gravity of 1.1 l, a weight of 9.3 pounds per gallon, and aviscosity of 2.75 Brookfield Centipoises.

The panels and 10' may have therewithin an electrical outlet box 32accessible from within the room of the dwelling. The electrical outletbox 32 is provided with a wireway conduit 33 extending from the top ofthe panel down to the outlet box 32 which in turn is generallyapproximately 18 inches from the lower end of the panel. It will benoted that the electrical outlet box 32 is flush with the inner facinglayer 30.

The panels 10 and 10' are made in the identical manner as follows:

Referring to FIG. 4, there is shown a portion ofa conveyor 34. Theconveyor 34 is preferably a conveyor supported in a convenient mannerwhereby it can withstand the weight of the panels as the panels areconstrueted. The conveyor 34 may be constructed ofa plurality of closelyfitting transverse slats. Conventional means may be utilized tointermittently move the conveyor 34 during the process of manufacturingthe panels 10.

The base sheet 36 of a material such as plywood is applied on top of theconveyor 34 so as to provide a uniform smooth surface. A form sheet 38is applied on top of the base sheet 36 as shown. The form sheet 38 ismade of a tough polymer which will not stick to the polyester mortar 24.I have found that Kydex, an acrylic-polyvinyl chloride alloy plasticsheeting material made by Rohm & Haas Company of Philadelphia, Pa., maybe used as the form sheet 38. Kydex will not stick to the polyestermortar.

Form sheet 38 is provided with upstanding intersecting ridges curved attheir top and designated by the numeral 10. Four such ridges 40 define apocket or cavity 42.

The form sheet 38 is provided with integral one-piece half bricks ofKydex 44 on its uppermost surface only along the side edges thereof. Thehalf bricks of Kydex 44 are positioned in every other row so as topartially define the cavities within which the bricks 18 will be appliedin the field.

Mold sides 46 and 48 are vertically disposed and c0- operate with moldends 50 and 52. The sides and ends are releasably interconnected withthe base sheet 36. The base sheet 36 is slightly larger than the formsheet 38 whereby the mold sides and ends rest on the upper periphery ofthe base sheet 36 and are removably attached thereto by suitablebrackets.

The bricks 22 are positioned in each of the pockets 42 and have a heightwhich corresponds to the height of the half bricks 44 as will beapparent from FIG. 6. The bricks 22 are preheated before they arepositioned in the cavities 42 so that they do not absorb heat from thefoam polymer 28, such as to a temperature of between to 180F, andpreferably about F. Thereafter, spline filler members 54 are positionedon top of the side edges of the bricks along the mold sides 46 and 48.The filler members 54 will define one-half of the cavity into which thespline 20 will be received. A reinforcing wire mesh 26 is applied to theupper surface of the layer ofthe bricks 22. See FIG. 8. Thereafter, thepolyester mortar 24 is sprayed or poured on top of the wire mesh 26above the bricks 22 and the filler bricks 44. The polyester mortarextends through the wire mesh 26 and adheres to the underlying bricks22, whereby the mesh becomes positioned within such mortar. The mortaris spread evenly so as to have a desired thickness, such as ofapproximately one-eighth to one-fourth inch thick. Mortar 24 also entersthe space between adjacent bricks and will be contoured by the roundedupper surface on the ridges 40 so as to simulate mortar which has beenpointed. The mortar 24 lends strength to the entire panel 10 whileintimately bonding adjacent bricks to one another.

The next step is to position the inner facing layer 30 on top of themold so that it is supported by the mold. If electrical outlet 32 is tobe part of the panel, the outlet and its wireway conduit are positionedin the space below layer 30 at this time. Thereafter, the conveyor 34will have moved to a position wherein a means will be provided to holdthe layer 30 in intimate contact with the sides and ends of the mold andprevent the entire composite from separating. Such means may be a platenor may be a series of rollers 58 as shown in FIG. 9. The length of therollers 58 should be sufficient to extend across the full width of thelayer 30 while being closely adjacent to one another for the full lengthof the layer 30.

Thereafter, a conduit 56 is introduced through a hole in one of the endssuch as a hole in the end 52. Conduit 56 is of sufficient length so thatit may extend to a position adjacent end 50 while being disposed withinthe space or cavity between layer 30 and the reinforcement mesh 26. Thefoam polymer such as foam polyurethane is then intermittently introducedthrough the conduit 56 at a frothing temperature of about l55F.* Eachtime the flow of foam polymer is terminated, the conduit 56 is withdrawnby a uniform amount. A sufficient number of such steps is repeated,namely discharging of foam polymer and then withdrawing a portion of theconduit 56, until the conduit 56 has been withdrawn through the openingin end 52. Thereafter, end 52 is closed in any convenient manner such asby threading a plug into the opening in end 52. By this time, mortar 24has cured.

*The optimum frothing temperature will vary with the nature of thepolyurethane foam, as will be appreciated by those having skill in theart thereof. Vertical tubular columns are then installed at spacedpoints along the bottom of the channel and support a steel frame systemfrom which the top channels 12 will be supported. The roofjoists arealso supported by the steel frame system.

The panels and 10 constructed in accordance with the present inventionare then slid along the top and bottom channels beginning from a cornerof the building. Appropriate spaces are left for windows and doors.L-shaped panels made in accordance with the present invention areutilized in the corners of the building. All of the components of thedwellings, such as the panels, channels, trusses, tubular columns, etc.,are factory constructed for ease of assembly at the job site. Twoadjacent panels may be interconnected by the spline and by field appliedbricks such as bricks 18 at the joint between adjacent panels. Also,mortar may be applied to the joint between adjacent panels. For ease ofinstallation, the panels may be numbered as to the sequence in whichthey will be installed.

The panels of the present invention are preferably made wholly fromincombustible materials and utilize a core having the minimum of voids,while at the same time providing proper insulation and having weatherresistance. The panels are capable of being fabricated from a wide rangeof mate rials, are easily transportable to the building site, and areeasily joined to adjacent panels with minimum skill required by theworkmen. The panels provide for maximum moisture resistance on the innerand outer surfaces and provide for resistance to fire, insects, anddecay.

When installed, the panels 10 and 10 are not load bearing elements ofthe building. The major thickness of the panels is comprised of foampolymer layer 28 and the mortar 24. These are the lowest densitycomponents of the panels; for example, closed cell urethane foam at anominal density of 2 pounds per cubic foot. Hence, it is possible bythe. present invention to construct panels having a relatively lowdensity while being highly resistant to moisture and to cracking.

If desired, foam polymer layer 28 may be introduced into the cavityabove mortar 24 by pouring the foam polymer utilizing an oscillatingnozzle instead of by l'rothing. If the foam polymer is poured, it willcontain an expansion delay agent which will delay expansion up to 2minutes. This will provide sufficient time to position the facing layer30 in place and secure the same to the mold sides and thereafter movethe conveyor so that force via the rollers or other devices may beapplied to prevent the layer 30 from rising when the foam polymerexpands.

A wide variety of urethane systems are available. For detaileddiscussion of such foam expansion delay agents, see Rigid Plastic Foams,by T. H. Ferrigno, Reinhold Publishing Corporation, Second Edition,1967, pages I12 through l 14. I prefer to use a system consisting ofHylene T.R.F. undistilled toluene disocyanate Selectrofoam 6500(SCl7-35)master batch sold by PPG Industries, Inc. In each alternative forintroducing the foam polymer into the cavity, the foam polymer isintroduced at a temperature of about 155F. and the cavity is closed bythe facing layer before the foam polymer expands. Any conventionalfoaming temperatures can be used, such as a temperature of between 50 to150F.

A thermo-setting unsaturated polyester resin that is cross linked withstyrene monomer is mixed. The proportions in this instance are percentby weight glass sand, 30 percent by weight Selectron No. 5265 polesterresin. Approximately 0.3 percent of methyl ethyl ketone peroxide is usedas catalyst to actuate the resin. However the percentage of methyl ethylketone peroxide will vary with regard to the desired setting time andtemperature of both the intermediate environment and materials beingused.

The properties of Selectron No. 5265 are:

1. Specific gravity 1.1 l

2. Weight 9.3 pounds per gallon 3. Viscosity 2.75 Brookfield CentipoisesThe polyester mortar described above provided a bond strength betweenadjacent bricks of 450 psi as compared to a bond strength of about 25psi attainable with cement mortars. Also, said polyester mixtureprovided a compressive strength approximately three times that of aPortland cement mortar.

In addition to strength, other attributes of the mortar 24 are:

a. fire resistance b. quick air-drying or curing (less than 30 minutes)c. attain high strength quickly so that panels may be handled shortlyafter completion (1. corrosion resistance e. toughness f. highresistance to ultraviolet rays of daylight g. freeze-thaw durability h.is not attacked by the foam polymer i. does not stick to the form sheet.

The subject panels had good fire resistance since they did not burnwhile having their edges exposed to 1,200F. for 5 minutes. After 40cycles of freezing and thawing, a Portland cement mortar showed signs ofdeteriorating while the subject panels showed no signs of deterioratingafter 94 cycles.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

I claim:

l. A prefabricated building panel adapted to be coupled with an adjacentbuilding panel to form the wall of a building, said panel having anouter weathering or facing layer to define the outer surface of abuilding, said panel having an inner facing layer to define the walls ofa room in a building, said outer facing layer being defined by aplurality of masonry members bonded together by a layer of polyestermortar, said mortar extending across the back of said masonry membersand in the space between adjacent members, a layer of closed cell foamurethane polymer between the layer of mortar and the inner facing layer,said foam polymer bonding said inner facing layer to said layer ofmortar, and a reinforcement wire mesh between said foam polymer andlayer of polyester mortar.

2. A building panel in accordance with claim 1 wherein said panel islonger than its width, said masonry members being rectangular brickswhich are thinner than their height, the long sides of the bricks beingperpendicular to the long sides of the panel, and the foam polymerhaving a slot for receiving a spline for joining two adjacent panelstogether.

3. A panel in accordance with claim 1 including a downwardly facing topchannel and an upwardly facing bottom channel, a plurality of saidpanels being disposed within said channels, and field applied masonrymembers applied in alternate rows interconnecting the side edges ofadjacent panels.

4. A prefabricated building panel adapted to be coupled with an adjacentbuilding panel to form the wall of a building, said panel having anouter weathering facing layer to define the outer surface of a building,said panel having an inner facing layer to define the walls of a room ina building and of a material different from said outer facing layer,said outer facing layer being thicker than the inner facing layer anddefined by a plurality of masonry members bonded together by a itswidth, said masonry members being rectangular bricks which are thinnerthan their height, the long sides of the bricks being perpendicular tothe long sides of the panel, and a layer of closed cell foam urethanepolymer between the layer of mortar and the inner facing layer, saidfoam polymer bonding said inner facing layer to said layer of mortar.

5. A building panel in accordance with claim 4 including a reinforcementwire mesh between said foam polymer and layer of polyester mortar.

6. A prefabricated building panel in accordance with claim 4 whereinsaid outer facing layer is thicker than said inner facing layer, saidpolymer and mortar being thicker than the combined thickness of thefacing lay- EI'S.

1. A PREFABRICATED BUILDING PANEL ADAPTED TO BE COUPLED WITH AN ADJACENTBUILDING PANEL TO FORM THE WALL OF A BUILDING, SAID PANEL HAVING ANOUTER WEATHERING OR FACING LAYER TO DEFINE THE OUTER SURFACE OF ABUILDING, SAID PANEL HAVING AN INNER FACING LAYER TO DEFINE THE WALLS OFA ROOM IN A BUILDING, SAID OUTER FACING LAYER BEING DEFINED BY APLURALITY OF MASONRY MEMBERS BONDED TOGETHER BY A LAYER OF POLYSTYRENEMORTAR, SAID MORTAR EXTENDING ACROSS THE BACK OF SAID MASONARY MEMBERSAND IN THE SPACE BETWEEN ADJACENT MEMBERS, A LAYER OF CLOSED CELL FOAMURETHANE POLYMER BETWEEN THE LAYER OF MORTAR AND THE INNER FACING LAYER,SAID FOAM POLYMER BONDING SAID INNER FACING LAYER TO SAID LAYER OFMORTAR, AND A REINFORCEMENT WIRE MESH BETWEEN SAID FOAM POLYMER ANDLAYER OF POLYESTER MORTAR.
 2. A building panel in accordance with claim1 wherein said panel is longer than its width, said masonry membersbeing rectangular bricks which are thinner than their height, the longsides of the bricks being perpendicular to the long sides of the panel,and the foam polymer having a slot for receiving a spline for joiningtwo adjacent panels together.
 3. A panel in accordance with claim 1including a downwardly facing top channel and an upwardly facing bottomchannel, a plurality of said panels being disposed within said channels,and field applied masonry members applied in alternate rowsinterconnecting the side edges of adjacent panels.
 4. A prefabricatedbuilding panel adapted to be coupled with an adjacent building panel toform the wall of a building, said panel having an outer weatheringfacing layer to define the outer surface of a building, said panelhaving an inner facing layer to define the walls of a room in a buildingand of a material different from said outer facing layer, said outerfacing layer being thicker than the inner facing layer and defined by aplurality of masonry members bonded together by a layer of polyestermortar, said mortar extending across the back of said masonry membersand in the space between adjacent members, said panel being longer thanits width, said masonry members being rectangular bricks which arethinner than their height, the long sides of the bricks beingperpendicular to the long sides of the panel, and a layer of closed cellfoam urethane polymer between the layer of mortar and the inner facinglayer, said foam polymer bonding said inner facing layer to said layerof mortar.
 5. A building panel in accordance with claim 4 including areinforcement wire mesh between said foam polymer and layer of polyestermortar.
 6. A prefabricated building panel in accordance with claim 4wherein said outer facing layer is thicker than said inner facing layer,said polymer and mortar being thicker than the combined thickness of thefacing layers.